i'm just about to rip out the clattering 2004 carb motor in my bike and fit a 2012 twin plug injected motor instead - I have all the bits and bobs along with the technical know how and tools but do any experts here have any good advice ?
May as well jack up the rad cap and roll a new bike under it........Oh, Yeah. You need a fuel tank with the electric fuel pump as well. No, you can't retrofit the vacuum operated one on the Volusia to work.
Long story short, just go buy another bike. You're about to spend a fortune re-inenting the wheel...
I see the clouds, but what's coming down doesn't exactly look like rain.Whoa. When you say you've got all the bits and bobs, I'm afraid you're missing a very important piece... A frame that will fit the engine.
Suzuki changed the frame, when they changed the engine to fuel injection in 2005. You can't put a modern motor, in the older frame. Sorry. Unless you plan to cut and weld, you're out of luck.
Plus, the engine swap will require the COMPLETE wiring harness for a 2012, including the ECU and all of the sensors. There are a number of additional changes as well, including LED lights on the 2012 model that the wiring harness is not designed to use normal incandescent bulbs....
Sorry to rain on your parade, but you're taking on Mission: Impossible.